Embedded lighting features for lighting panels

ABSTRACT

Lighting panels and methods of manufacturing lighting panels are described. An example lighting panel includes a substrate that has a planar surface, electrically conductive traces printed onto the planar surface of the substrate, and light sources mounted onto the electrically conductive traces at mounting positions such that the electrically conductive traces form an electrical interconnection between selected ones of the electrically conductive traces and associated ones of the light sources. The lighting panel also includes a polymer sheet provided over the light sources, and a composite base upon which a stack-up of the substrate with the printed electrically conductive traces, the light sources, and the polymer sheet is applied. The light sources are embedded into the composite base and are also flush with a top surface of the stack-up, and the substrate is also embedded into the composite base underneath the light sources at the mounting positions.

FIELD

The present disclosure generally relates to interior lighting panels forpassenger aircraft, and more particularly, to aircraft ceiling, stowbin, valences, sidewalls or other mounted lighting panels adapted todisplay a starry nighttime sky effect.

BACKGROUND

Passenger aircraft that operate over long distances during the nighttypically include interior lighting arrangements that providesubstantially reduced ambient light so that passengers can sleepcomfortably, but which is still bright enough to enable those passengerswho choose not to sleep to move about the cabin safely. For example,some models of passenger jets incorporate ceiling panels thatincorporate light emitting diodes (LEDs) arranged so as to blink inrandom patterns against a gray or dark blue background, and which, in areduced ambient light condition, gives the relaxing, soporificappearance of a starry nighttime sky, and hence, is referred to as a“Starry Sky” ceiling lighting arrangement.

A conventional Starry Sky lighting panel may include complex discretewiring and electrical components located on a back surface thereof. Thepanel may use lenses, lens holders, hardwired LEDs, and wire bundlesdeployed on individual standoffs, and discrete power conditioning andcontrol components that are integrated in a relatively complicatedmanufacturing process to produce a panel that gives the desired effect.In a typical installation, the aircraft may contain many of such panels,each of which may contain many LEDs. A typical Starry Skies ceilingpanel feature requires the LEDs to be manually installed in the panel.

The disadvantages and limitations of these solutions are that the methodof producing the panel is costly and relatively heavy, requiresintensive, ergonomically costly manual labor steps due to the amount ofmanually installed wire, takes up a relatively large volume behind theceiling panels and is difficult to retrofit into existing aircraft.Because of the mass and volume of the wires for this system, it istypically limited to only be installed in ceilings.

In light of the foregoing, there is a need in the relevant industry foran aircraft ceiling lighting panel that provides a Starry Sky effectthrough a “solid state” method that does not use lenses, lens holders,wired LEDs and complex associated point-to-point wiring, reduces panelweight, volume, manual fabrication and assembly labor and cost,eliminates repetitive injuries, and which can easily be retrofitted intoexisting aircraft.

SUMMARY

In one example, a lighting panel is described comprising a substratehaving a planar surface, a plurality of electrically conductive tracesprinted onto the planar surface of the substrate, and a plurality oflight sources mounted onto the plurality of electrically conductivetraces on the planar surface of the substrate at mounting positions suchthat the plurality of electrically conductive traces form an electricalinterconnection between selected ones of the plurality of electricallyconductive traces and associated ones of the plurality of light sources.The lighting panel includes a polymer sheet provided over the pluralityof light sources, and a composite base upon which a stack-up of thesubstrate with the printed plurality of electrically conductive traces,the plurality of light sources mounted on the planar surface, and thepolymer sheet is applied. The plurality of light sources are embeddedinto the composite base and are also flush with a top surface of thestack-up, and the substrate is also embedded into the composite baseunderneath the plurality of light sources at the mounting positions.

In another example, a method of manufacturing a lighting panel isdescribed. The method comprises printing a plurality of electricallyconductive traces onto a planar surface of a substrate, mounting aplurality of light sources onto the plurality of electrically conductivetraces on the planar surface of the substrate at mounting positions suchthat the plurality of electrically conductive traces form an electricalinterconnection between selected ones of the plurality of electricallyconductive traces and associated ones of the plurality of light sources,providing a polymer sheet over the plurality of light sources, andproviding a stack-up of the substrate with the printed plurality ofelectrically conductive traces, the plurality of light sources mountedon the planar surface, and the polymer sheet onto a composite base. Themethod also includes applying pressure and heat to the stack-up and thecomposite base to embed the plurality of light sources into thecomposite base so as to be flush with a top surface of the stack-up, andto embed the substrate into the composite base underneath the pluralityof light sources at the mounting positions.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE FIGURES

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and descriptions thereof, will best be understood byreference to the following detailed description of an illustrativeembodiment of the present disclosure when read in conjunction with theaccompanying drawings, wherein:

FIG. 1 illustrates a portion of an example process for manufacturing alighting panel, in which a substrate is shown that has a planar surface,according to an example embodiment.

FIG. 2 illustrates another portion of the example process formanufacturing a lighting panel, in which a plurality of light sourcesare mounted onto the plurality of electrically conductive traces on theplanar surface of the substrate at mounting positions, according to anexample embodiment.

FIG. 3 illustrates another portion of the example process formanufacturing a lighting panel, in which a polymer sheet is providedover the light sources, according to an example embodiment.

FIG. 4 illustrates another portion of the example process formanufacturing a lighting panel, in which a composite base is providedupon which a stack-up of the substrate with the printed plurality ofelectrically conductive traces, the light sources mounted on the planarsurface, and the polymer sheet is applied, according to an exampleembodiment.

FIG. 5 illustrates another portion of the example process formanufacturing a lighting panel, in which the light sources are embeddedinto the composite base and are also flush with a top surface of thestack-up, and the substrate is also embedded into the composite baseunderneath the light sources at the mounting positions, according to anexample embodiment.

FIG. 6 illustrates another portion of the example process formanufacturing a lighting panel, in which a decorative film can also beapplied over the polymer sheet to cover the light sources, according toan example embodiment.

FIG. 7 illustrates a top view of the substrate with electricallyconductive traces, according to an example embodiment.

FIG. 8 illustrates the substrate with a circuit including light sources,according to an example embodiment.

FIG. 9 shows a flowchart of an example method for manufacturing alighting panel, according to an example embodiment.

DETAILED DESCRIPTION

Disclosed embodiments will now be described more fully hereinafter withreference to the accompanying drawings, in which some, but not all ofthe disclosed embodiments are shown. Indeed, several differentembodiments may be described and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments aredescribed so that this disclosure will be thorough and complete and willfully convey the scope of the disclosure to those skilled in the art.

Within examples, a lighting panel and a method of manufacturing alighting panel are described. The lighting panel comprises a substratehaving a planar surface, a plurality of electrically conductive tracesprinted onto the planar surface of the substrate, and a plurality oflight sources mounted onto the plurality of electrically conductivetraces on the planar surface of the substrate at mounting positions suchthat the plurality of electrically conductive traces form an electricalinterconnection between selected ones of the plurality of electricallyconductive traces and associated ones of the plurality of light sources.A polymer sheet can be provided over the plurality of light sources. Acomposite base is provided upon which a stack-up of the substrate withthe printed plurality of electrically conductive traces, the pluralityof light sources mounted on the planar surface, and the polymer sheet isapplied. The plurality of light sources are embedded into the compositebase and are also flush with a top surface of the stack-up, and thesubstrate is also embedded into the composite base underneath theplurality of light sources at the mounting positions.

Example lighting panels described integrate light sources into crushcore panels to create a lighting effect that may be used for interiorpanels of aircraft, for example. Example methods for manufacturingdescribed herein may use a plastic film with printed traces and bondedlight sources that are then integrated into a panel via a method ofcrush core processing with composites. A decorative layer can then beapplied over the light sources. This process can be used to integrate alighting feature similar to Starry Skies into any crush core aircraftpanels (e.g., ceilings, stow bins, valences, sidewalls, etc.).

Thus, in some examples, the disclosure relates to “Starry Sky” aircraftceiling panel lighting systems and methods for manufacturing them. Thelighting panels comprise a plurality of small light sources, such asmicro-miniature light emitting diodes (LEDs), or alternatively, organiclight emitting diodes (OLEDs), and together with control circuitryconnected with conductive traces that are printed or otherwise formedonto an aircraft structural ceiling panel and/or to a lamination offlexible substrates that are then bonded to such a structural ceilingpanel in the form of an appliqué therefor. The result is a Starry Skylighting panel construction that is lighter, smaller, less expensive,and easier to retrofit to existing aircraft than existing Starry Skylighting panel systems.

Referring now to FIGS. 1-6, an example process is shown formanufacturing a lighting panel, according to an example embodiment. InFIG. 1, a substrate 200 is shown that has a planar surface 202. Theplaner surface 202 provides a relatively smooth surface or substantiallyflat surface.

As used herein, by the term “substantially” it is meant that the recitedcharacteristic, parameter, or value need not be achieved exactly, butthat deviations or variations, including for example, tolerances,measurement error, measurement accuracy limitations and other factorsknown to skill in the art, may occur in amounts that do not preclude theeffect the characteristic was intended to provide. Similarly, the term“about” includes aspects of the recited characteristic, parameter, orvalue allowing for deviations or variations, including for example,tolerances, measurement error, measurement accuracy limitations andother factors known to skill in the art, and also ranges of theparameters extending a reasonable amount to provide for such variations.

The substrate 200 may comprise a polymer film, or a polyvinyl fluoride(PVF) material, such as Tedlar film (Du Pont Tedlar polyvinyl fluoride(PVF)), for example. Other flexible, dielectric substrate materials mayalso be used for the substrate 200, such as, for example, Kapton, Mylaror polyvinyl chloride (PVC) materials.

A plurality of electrically conductive traces 204 are printed onto theplanar surface 202 of the substrate 200. Electrically conductive traces204 are shown in FIG. 7. The electrically conductive traces 204 can bewritten on the planar surface 202 of the substrate 200 so as to makeelectrical connections with respective leads of electrical components(i.e., anode and cathode of LEDs).

One or more of several conductive trace writing methods may be used toprint the electrically conductive traces 204 on the substrate 200. Inone example, plasma spraying may be used to deposit a wide range ofconductive or non-conductive materials directly onto conformal surfaces.In another example, aerosol spraying can also be used to deposit a widerange of materials with extremely fine (e.g., 4-5 micron) feature size,either on flat substrates or on conformal surfaces. In still anotherexample, ink jet printing technology can also be used to print to flatsubstrates, which may then be adhered to conformal surfaces. Andfinally, as another example, screen printing of conductive inks may beused to print to polymer film which is then adhered to a conformalsurface. Any combination of such techniques may also be used. Printedelectronics allows the use of flexible substrates, which lowersproduction costs and allows fabrication of mechanically flexiblecircuits.

As shown in FIG. 2, a plurality of light sources 206 and 208 are mountedonto the plurality of electrically conductive traces 204 on the planarsurface 202 of the substrate 200 at mounting positions 210 and 212 suchthat the plurality of electrically conductive traces 204 form anelectrical interconnection between selected ones of the plurality ofelectrically conductive traces and associated ones of the plurality oflight sources. The electrically conductive traces 204 may comprisegroups of circuits, and the light sources 206 and 208 are mounted ontothe electrically conductive traces 204 so as to form the groups ofcircuits. As an example, FIG. 8 illustrates the substrate with a circuitincluding light sources 214, 216, and 218. Multiple circuits may beincluded based on interconnection of various light sources.

The electrically conductive traces interconnect the light sources 206and 208 with power and control circuitry such that each light source 206and 208 can be controlled independently of the other, and can be causedto blink or “twinkle.” Alternatively, groups of associated light sourcein the panel can be controlled independently of each other.

The light sources 206 and 208 may include light emitting diodes (LEDs),organic light emitting diodes (OLEDs), other surface mounted devices(SMDs), or a combination of each. The light sources 206 and 208 may bemounted using a conductive adhesive, and the resulting substrate-lightsource assembly may be cured, e.g., by UV radiation, if UV curingadhesives are used, or alternatively, may be cured with heat, forexample, in an autoclave process.

As shown in FIG. 3, a polymer sheet 220 is provided over the lightsources 206 and 208. The polymer sheet 220 can be a clear polymer sheet,and laid over the light sources 206 and 208 for attachment through afinal process (described below).

As shown in FIG. 4, a composite base 222 is provided upon which astack-up 224 of the substrate 200 with the printed plurality ofelectrically conductive traces 204, the light sources 206 and 208mounted on the planar surface 202, and the polymer sheet 220 is applied.The composite base 222 may comprise an existing aircraft structuralceiling panel, made of, e.g., a polycarbonate or polyurethane plastic.As another example, the composite base 222 may comprise a honeycomb corepanel. The composite base 222 may include any composite material, suchas a lightweight material like an uncured pre-impregnated reinforcingtape or fabric (i.e., “prepreg”). The tape or fabric can include aplurality of fibers such as graphite fibers that are embedded within amatrix material, such as a polymer, e.g., an epoxy or phenolic. The tapeor fabric could be unidirectional or woven depending on a degree ofreinforcement desired.

As shown in FIG. 5, using a crush-core process, the light sources 206and 208 are embedded into the composite base 222 and are also flush witha top surface of the stack-up 224, and the substrate 200 is alsoembedded into the composite base 222 underneath the light sources 206and 208 at the mounting positions 210 and 212. For example, portions 226and 228 of the substrate 200 are embedded into the composite base 222underneath the light sources 206 and 208 at the mounting positions 210and 212.

The crush core process includes placing the composite base 222 with thestack-up 224 in a large press, and the stack-up 224 is crushed down intothe composite base 222 to a predetermined thickness. Example pressuresup to 300 psi/20.7 bar cause honeycomb cell walls of the composite base222 to fold over and flatten, creating more bonding surface area for thestack-up 224. This method creates panels of consistent thickness,ensuring good fit and finish during installation. Thus, using the crushcore process, the stack-up 224 is bonded into the composite base 222using pressure and heat to cure the bond.

As shown in FIG. 5, the polymer sheet 220 covers the light sources 206and 208. The light sources 206 and 208 are in contact with the polymersheet 220 and are operated to shine light 230 through the polymer sheet220. No holes are provided in the polymer sheet 220 that expose thelight sources 206 and 208. In addition, no pockets or potting of thecomposite base 222 are required for insertion of the light sources 206and 208. Rather, the crush core process embeds the light sources 206 and208 into the composite base 222 with corresponding portions 226 and 228of the substrate 200 embedded underneath the light sources 206 and 208to provide electrical connections. Without the need for pre-drilledholes or pre-formed pockets, additional manufacturing steps can beremoved. The ability to integrate the light sources 206 and 208 into thecomposite base 222 without requiring a pocket or potting of the lightsources 206 and 208, or other apertures or lenses enables the panel tobe manufactured more efficiently.

As shown in FIG. 6, a decorative film can also be applied over thepolymer sheet 220 to cover the light sources 206 and 208. In thisexample, the decorative film 232 may be a clear or decorative laminate(“declams”) comprising a thin, flexible film, such as Du Pont Tedlarpolyvinyl fluoride (PVF). The decorative film 232 also does not requireany small apertures, or vias through which the light sources 206 and 208are respectively exposed. The decorative film 232 can be bonded to thepolymer sheet 220 using an adhesive. FIG. 6 illustrates a completedlighting panel 234. In other examples, the decorative film 232 may bereplaced with a layer painted on for decoration.

FIG. 9 shows a flowchart of an example method 300 for manufacturing alighting panel, according to an example embodiment. Method 300 shown inFIG. 9 presents an embodiment of a method that, for example, could beused within the processes shown in FIGS. 1-6, for example. Method 300may include one or more operations, functions, or actions as illustratedby one or more of blocks 302-310. Although the blocks are illustrated ina sequential order, these blocks may also be performed in parallel,and/or in a different order than those described herein. Also, thevarious blocks may be combined into fewer blocks, divided intoadditional blocks, and/or removed based upon the desired implementation.

It should be understood that for this and other processes and methodsdisclosed herein, flowcharts show functionality and operation of onepossible implementation of present embodiments. Alternativeimplementations are included within the scope of the example embodimentsof the present disclosure in which functions may be executed out oforder from that shown or discussed, including substantially concurrentor in reverse order, depending on the functionality involved, as wouldbe understood by those reasonably skilled in the art.

At block 302, the method 300 includes printing the plurality ofelectrically conductive traces 204 onto the planar surface 202 of thesubstrate 200. As an example, the electrically conductive traces 204 maybe screen printed as silver ink on a Tedlar substrate or other polyvinylfluoride (PVF) material. The electrically conductive traces 204 may beprinted to provide connections to electrical components (or to terminalsof electrical components), so that the electrical components can beplaced randomly across the substrate 200.

At block 304, the method 300 includes mounting the plurality of lightsources 206 and 208 onto the plurality of electrically conductive traces204 on the planar surface 202 of the substrate 200 at mounting positions210 and 212 such that the plurality of electrically conductive traces204 form an electrical interconnection between selected ones of theplurality of electrically conductive traces and associated ones of theplurality of light sources. The light sources 206 and 208 may be mountedusing a conductive epoxy. The electrically conductive traces 204 may beprinted to result in groups of circuits, and the light sources 206 and208 are mounted onto the electrically conductive traces 204 so as toform the groups of circuits. The electrically conductive traces 204 maybe printed so as to result in four groups of circuits that areindependent and not wired in parallel, for example.

At block 306, the method 300 includes providing the polymer sheet 220over the plurality of light sources 206 and 208. The polymer sheet 220protects the electrically conductive traces 204 and the light sources206 and 208 from sweep/sand and paint processes applied to a finalproduct of the lighting panel. The polymer sheet 220 can be a clearpolymer sheet, and covers the light sources 206 and 208 so that thelight sources 206 and 208 are in contact with the polymer sheet 220 andshine light through the polymer sheet 220.

At block 308, the method 300 includes providing the stack-up 224 of thesubstrate 200 with the printed plurality of electrically conductivetraces 204, the plurality of light sources 206 and 208 mounted on theplanar surface 202, and the polymer sheet 220 onto the composite base222. The composite base 222 may include a honeycomb core panel.

At block 310, the method 300 includes applying pressure and heat to thestack-up 224 and the composite base 222 to embed the plurality of lightsources 206 and 208 into the composite base 222 so as to be flush with atop surface of the stack-up 224, and to embed the substrate 200 into thecomposite base 222 underneath the plurality of light sources 206 and 208at the mounting positions 210 and 212. Pressure and heat may be appliedusing a crush core process. When the materials are removed from thepress, the light sources 206 and 208 are flush with the top surface andembedded into the composite base 222.

The ability to integrate the light sources 206 and 208 into thecomposite base 222 without requiring pockets or pre-drilled holes formedfor the light sources 206 and 208, and no need for potting of the lightsources 206 and 208 allows for integration of the substrate 200 andlight sources 206 and 208 into the composite base 222 in a manner toreduce weight, size, and cost of prior systems. Further, with no pocketscreated, then additional encapsulation with a potting material is alsoavoided. The light sources 206 and 208 can be crushed directly into thecomposite base 222 which allows for integration without use of a pocketand potting material and has been shown to provide a better surfacefinish.

In addition, the light sources 206 and 208 are bright enough to not needa hole to be cut in any top layer or coating which further simplifiesthe design. Thus, there is no need for holes or lenses or otherstructures to project light through the polymer sheet 220 since thelight sources 206 and 208 directly contact the polymer sheet 220.

A decorative film 232, or paint, may then be applied to a top surface ofthe polymer sheet 220, which enables painting by protecting theelectronics. Connectors can then be installed for power and operation ofthe lighting panel.

As those of skill in the art will also appreciate, there are numerousother fabrication and assembly options available that will arrive at thesame or a substantially similar lighting panel 234 configuration.

The lighting panel 234 may include a power and control module insert 236for supplying electrical power and control signals to the light sources206 and 208 of the lighting panel 234. This enables the printedelectrically conductive traces 204 to be connected to wiring. Stillfurther, other discrete electrical components, e.g., microprocessors andRF control or transceiver components to power and control the lightsources 206 and 208, can be embedded into the power and control moduleinsert 236. The power and control module insert 236 may furtherincorporate terminal input/output connection pads that enable easyelectrical interconnection between the power and control module insert236 and the light sources 206 and 208 via the electrically conductivetraces 204.

As those of skill in the art will appreciate, many aircraft systems canprovide electrical power and control signals to light fixtures or thelighting panel 234. Electronics located within the light panel 234, suchas within the power and control module insert 236, can control color andbrightness of emitted light. Pulse width modulation can be used tocontrol brightness of each of the light sources 206 and 208 within thelighting panel 234. Furthermore, an aircraft ceiling may include manylighting panels, and each lighting panel may be individually controlled.

Control over the lighting panel 234 (typically involving overall starfield brightness and blink rate) may be effected, for example, bytransmitting control commands or settings from the aircraft to thelighting panel 234 via a wireless link and received at the power andcontrol module insert 236. In one example, the power and control moduleinsert 236 includes a radio receiver that receives such commands orsettings. An antenna for the radio may be printed directly on thesubstrate 200 or on a substrate laminated thereto, along with otherelectrical conductors and components.

In another example, control of the lighting panel 234 may be effected bytransmitting control commands or settings from the airplane to the panelvia communication over power line (COPL) technology. Electronics of theaircraft superimpose control/setting signals over a power signal to thelighting panel 234. A COPL transceiver located in the power and controlmodule insert 236 interprets these signals and controls the lightsources 206 and 208 accordingly.

The lighting panel 234 offers a number of advantages over prior lightingpanels. Components of the lighting panel 234 are less expensive(excluding investment in capital equipment). The current manufacturingprocess has high ergonomic cost factors, including fine detail,repetitive motions and the like which are substantially eliminated inthe examples disclosed herein.

Additionally, integration of direct write electronics and theelectrically conductive traces 204 into the lighting panel 234 hasseveral additional benefits, including reduced panel weight, shorterprocess flow times, improved durability, a more efficient form factorand improved ergonomics of manufacture. In the past, some aircraftcustomers have not selected the Starry Sky lighting option because ofthe weight penalty associated therewith. The lighting panel 234 canprovide a weight savings per panel, which, in an aircraft equipped withnumerous such panels, results in an appreciable weight savings overprior panels.

Further, as described above, in some examples the lighting panel 234 mayhave a wired supply of electrical power and a wireless, e.g., radio,interface for communication and control. Thus, the lighting panel 234requires a low voltage electrical interface for power, and power can betapped from existing sources, such as ceiling wash lights that aretypically turned down to low power while the starry sky effect isoperating. Tapping power from local sources and providing wirelesscontrol simplifies retrofit of existing aircraft by reducing the need torun additional aircraft wiring.

While various examples of the lighting panel disclosed herein aredescribed and illustrated in the context of aircraft interior ceilinglighting systems, it will be evident that they are not limited to thisparticular application, but may be used in a variety of otherapplications, e.g., other aircraft surfaces, such as entry areaceilings, destination spaces, or even in non-aerospace applications,such as dance halls theaters residential ceilings, advertisements, andthe like.

The description of the different advantageous arrangements has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different advantageousembodiments may describe different advantages as compared to otheradvantageous embodiments. The embodiment or embodiments selected arechosen and described in order to explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A lighting panel, comprising: a substrate havinga planar surface; a plurality of electrically conductive traces printedonto the planar surface of the substrate; a plurality of light sourcesmounted onto the plurality of electrically conductive traces on theplanar surface of the substrate at mounting positions such that theplurality of electrically conductive traces form an electricalinterconnection between selected ones of the plurality of electricallyconductive traces and associated ones of the plurality of light sources;a polymer sheet provided over the plurality of light sources; and acomposite base upon which a stack-up comprising (i) the substrate withthe printed plurality of electrically conductive traces, (ii) theplurality of light sources mounted on the planar surface, and (iii) thepolymer sheet is applied, wherein the plurality of light sources areembedded into the composite base and are also flush with a top surfaceof the stack-up, and the substrate with the plurality of electricallyconductive traces is also embedded into the composite base with theplurality of electrically conductive traces underneath the plurality oflight sources at the mounting positions.
 2. The lighting panel of claim1, wherein the substrate comprises a polymer film.
 3. The lighting panelof claim 1, wherein the plurality of electrically conductive tracescomprise groups of circuits, and wherein the plurality of light sourcesare mounted onto the plurality of electrically conductive traces so asto form the groups of circuits.
 4. The lighting panel of claim 1,wherein the plurality of light sources comprise light emitting diodes(LEDs), organic light emitting diodes (OLEDs), or a combination of each.5. The lighting panel of claim 1, wherein the polymer sheet is a clearpolymer sheet.
 6. The lighting panel of claim 1, wherein the polymersheet covers the plurality of light sources.
 7. The lighting panel ofclaim 1, further comprising a decorative film applied over the polymersheet.
 8. The lighting panel of claim 1, wherein the lighting panelcomprises an aircraft structural ceiling panel.
 9. The lighting panel ofclaim 1, wherein the composite base comprises a honeycomb core panel.10. The lighting panel of claim 6, wherein the plurality of lightsources are in contact with the polymer sheet and shine light throughthe polymer sheet, wherein the polymer sheet is a single piececonstruction.